Full report

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General Disclaimer One or more of the Following Statements may affect this Document This document has been reproduced from the best copy furnished by the organizational source. It is being released in the interest of making available as much information as possible. This document may contain data, which exceeds the sheet parameters. It was furnished in this condition by the organizational source and is the best copy available. This document may contain tone-on-tone or color graphs, charts and/or pictures, which have been reproduced in black and white. This document is paginated as submitted by the original source. Portions of this document are not fully legible due to the historical nature of some of the material. However, it is the best reproduction available from the original submission. Produced by the NASA Center for Aerospace Information (CASI)

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THE SOLAF HATTNG AND N78-164 .5 fIASA.-TM-7815?) (1 0LININ -^CMM1FCIAL DE1CNS11, A1ICN PFCGF.AM: `^E FARTY PFCFLEC'; AND RESULTS (NASA) j1 F C?/1F A01 DOE/NASA TM-78152 CSCL 10A Onclas 63/44 02585 THE SOLAR HEATING AND COOLING COMMERCIAL DEMONSTRATION PROGRAM -- SOME EARLY PROBLEMS AND RESULTS By Robert l.. Middleton Solar Heating and Cooling Project office Prepa rod by the ti131A4%6 l,,^^^^ y FEES 1978 0 National Aeronautics and Space Administration George C. Marshall Space Flight Center. Alabama :35812 for the I)eparment of F.nerkry Pri- . y i ► ^*-# , U.S. Department of Energy RfIF _ _t Solar Energy

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TECHNICAL_ NEPORT S7ANDARD TITLE 'Ak. i PEPORr NO 2, 30YERNWNT ACCESSION NO, S. NASA 7'hi 1 '4 1: q TI TLE AND SUBTITLE RECIPIENT'S CATALOG NO. 5, FEPORT DATE and Cooling Commercial Demonstration .J:Inunry 197.9 The Solar Heating 6 PERFORMING, ORGANIZATION CEIDE Program -- Sunic Farb Problems and Results AUTNOR(S) 4-- Robert L. Middleton $ PERFORMING ORGANIZATION REP rlta 11 PCRCIRMING ORGANIZATION NAME AND ADDRESS 10, WORK UNIT NO. 9 George C. Marshal l Space F light Center 1 1. CONTRACT OR GRANT N0. Marshall Space Flight Center, Alabama 35412 1 SPONSORING AGENCY NAME AND ADDRESS 13 , TYPE OF REPOR, b PERIOD COVERED Technical Memorandum %ationa) Aeronautics and Space. Administration Washington , D. C. 20546 15 SUPPLEMENTARY NOTES 1.1- +PONSORING AGENCY CODE ( Prepared by Solar heating !md Co ohnI4 Project Office, Special Projects Office 16 AR STIR The origination of the Solar cleating and Cooling Cormercial Demonstration Program by the Energy Research and Development Administration and the subsequent activities of the Marshall Space Flight, Center of the National Aeronautics and Space Administration in the technical evaluation of proposals, contracts definitions, and program management details are defined and discussed. During; the period from initial site selection to present, a significant amount of experience has been gained which should Nc published to assist others in avoiding these problems. The significant problems are summarized in both technical and management aspects of the program. it is concluded that the program has Significantly stimulakd additional solar effort by tlu , program particilr.lnts. It is also concluded that the use of conventional construction industry organizations with design/competitive bid procedures and standards has maintained a cost effective prok-ram. 17 i-EN WORDS Solar Energy Solar Demonstration Solar Heating and Fooling 1y SECURIT Y CLASSIF. (of tht n reportl 20 Unclassified nI.SF(! - Farm a1S2 IRr, Der,rrtbrr 1972) T^ 18 DISTRIBUTION STATEMENT Unclassified — Unlimited 4ECJRITY CLASSIF, (of thl• pe¢ii) 21- NO. OF PAGES 22 PRICE Unclassified 31 NTIS Fnf Sale by National rechnical Inf,,rm atinn Sewice, SprinRfiNd, Virginia 2211;

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TABLE OF CONTENTS page IN '1'11OUI?( nON ............. 4 • • . . . . . . . . . . . . . . . . . . . . . 1 DISCUSSION ....................................... liminary Design Review . • • • . • . . • • • • • • . • . • . . . . . . I Design Phase • • • . • .... • • • • • . • • • . • . .. ... i Final Design Review .......................... .. . 4 Competitive: Bidding, Construction Contract Award, and Construction Phase .... 4 4 4 4 ...... • . . . • . • 0 0 ....... 5 Acceptance Test Phase ..................... .. ... 5 Operational Phase . 4 0 4444 .. 0 0 0 0 .. 4 . 4 0 0 4444 ... G NCLJTSIONS......0..4.•.•.4....40••..•00.•....... 7 REFERENCES ....... . . . . . . . . . . . . • . . . . . • • • . . . . • . . . • . 26 iii

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L I ST OF ILLUSTRATIONS Fiore Title Page 1. Site data acquisition system . • . . . . . . . . e • • • • • . . . 9 2. Sensor to user data system • . . . . . . . . . . . . . . . . . . . . . 10 L ST OF TABLES Title Page T able 1. Project Information Summary.. . . . • • • . . • . . . . . . . . . . 11 2. Project Status Summary .............. 17 1 0 .. 9 . • . . . 3. Swum:wy of Significant Technical/Design Problems and Solutions for the Solar Heating and Cooling Commercial Demonstration Program — First Year — To Date ..... 0 .. 0 0 0 . . • • • . . . • . . . . • . • . 23 'I. Summary of Significant Management Problems, and Solutions for Solar Heating and Caroling Commercial Demonstration I'rograni ...... . iv

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TECUNICAL MEMORANDUM 713132 THE SOLAR HEATING AND COOLING COMMERCIAL DEMONSTRATION PROGRAM — SOME EARLY PROBLEMS AND RESULTS INTRODUCTION Ihis report presents a summary of the effort by bath :the Energy Research Id Development Administration ( ERDA)i and the National ;Ne'ronautics and Spacer 11ninistration (NASA), Marshall Space Flight Center (MSFC), personnel who attempted to define and implement, in a short time, an envrgy program of mitional urgency thA had no precedent in Government-Industr .v relationships and procedures. ;Many individuals from h:PDA and AISFC have contributed significant amounts of personal time to structure and implement this program, and their contributions are recognized and appreciated. DISCUSSION The Commercial Solar Beating; and Cooling; Demonstration Program way initiated by ERDA Program Opportunity Notice ( PON) [ I I in October 1975. The overall program currently calls for approximately yearly releases of PON's over a 4 year period. The second PON 121 was released in October 1976, and the selection process is now being completed by EMDA. AISFC, which had participated in earlier solar heating; and cooling; activities, was asked by the ERDA tc, perform technical vv:iluation of the approximately 300 responses to the PON for the first and second years. ERDA used the results of the AISFC technical evaluation in addition to other criteria in selecting; the demonstration sites for the first and second year. Following; the: first year selectior by ERDA of the 32 winning sites in March of 1976, 2%1SFC was asked by ERDA to define a contractual relationship for each site that was unique in government contractual procedures, and to manage the prog;rzum through the successful operation of each site. The contract relationship was expected to have the following; characteristics: 'ERDA was absorbed by the newly formed Department of V.nerg;y ( DOE) , Oct 1, 1978.

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a. Cost shau'ing — In most cases, the Government would provide+ the major funding; for the design and installation of a solar system into each site. Each site owner/team would receive the reduced utility cost of the project, plus the intangible return of public relations and pionevi-ing; industry experience. The maximum degree of cost ~haring; was desired. b. Cost effectivity — 'The program was aimed at installing; available solar components with existing; Heating, Ventilation and Air Conditioning (11VAC) industry standard hardware and procedures. If these government contracts were significantly over-funded by either inaccurate cost estimates or tainecessary requirements, then the new solar industry could and would be initiated with a cost bias that would require ,years to overcome and achieve competitive cost with conventional energy. c. Contract requirements workable with small business -- Several of the selected sites wore proposed by organizations with no ex1wriencc- with government contracts. All aspects of the contracts therefore had to be applicable and workable "ith small organizations and individuals with no government contract experience. d. Cost effective installation of the performance measuring; sensors and Site Data Acquisition System (SUAS) — 'I'he PON reference stated that thf, Goverm»cnt might provide hardware to measure the solar system performance at any Site. The decision was made by ERDA to supply each site for a period of time with the performance measuring sensors and equipment to record and transmit the performance data to a central computer processing; site. Fig =ures 1 and 2 show the equipment and its operation while References 3 and 4 provide definitive details. e. i<laximize the success probability of each site — It is believed chat providing; assistance to each site (both technical and management) significantly increases the success probability of each site. Sonic of the methods used were developed in the space program and others utilized conventional construction industry procedures. f. Utilize conventional construction industry procedures, standards, and terminology — The PON specified the participation of professionally qualified architects and engineers. Therefore, the entire program must be structured to utilize and operate within the "construction" industry procedures, terminology, and standards. In addition, the project must conform to all a}pplicahle local codes and the interim Performance Criteria of Reference 5. 2

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The; A1SFC personnel assigned to prepare the contract documents (and essentially define- the progrtuii :structure and procedures) recognized that previous management capericnce with space related development projects was not adequate, for this unique, conventional industry program. Therefore, a conference was arranged at A1SFC in early Alarch 1976 before the contract document preparation with representatives of they professional societies and industry organizations currently operating in the IIVAC area of the related construction industry. The participating organizations were: a. American Society of Heating, liefrigeration and A ► rconditioning Engineers (ASIMAE) I,. American Institute of Architects (AIA) c. Mechanical Contractors Association of America (AICAA) d. Sheet AlU-tal, Aix-conditioning Contractors National Association (SMACNA) The desired progr:nm goals and gener:d pl: ► ns to operate with conventional construction industry procedures were discussed with the representatives of these organizations. They lollowing specific points were discussed with representatives of the above organizations mid their organization recommemlatiom; for the program were received for inclusion in the program: a. :'Architect and engineer design procedures and standards 10. Project cost evaluation and control procedures e. Competitive bidding procedures d. Initial system operations and check out procedures. The review of the program with the technical societies and industry associations provided inv.Livable insight into methods of accomplishing the desired program goals. It was decided to utilizer the professional experience of selected me-mbers of the ASURAE and the AIA in the actual program in ►plementation. 'Phis permitted individuals with extensivc industry experience to provide constructive technical beer group inputs and suggestions into each selected site and to permit a broader awareness and utilization of each project rite experience. The major program elements were in general as follows. 3

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Preliminary Design Review This review was to be held at the project site. For some complex projects, one or two memlxrrs of ASIMAI, and MA (selected 1y their National Headquarters) attended the preliminary and final design review to offer constructive suggestions. The purpose of the review wu.s to discuss the project concept including: a. Collector tilt mgle, location, and size 1,. Storage tank type, size, and location c. Control procedures, operating modes, and control parameters d. Performance variations for changes in collector, storage, and airconditioning or heating system e. Project schedule f. Planned Government furnished performance measuring instrkuuentation and Site Data Acquisition System (shown in Fii;u -es 1 and 2 amid defined in References 3 and 4) Required project design compliance witli the Interim Perform. Criteria (51 and all state and local codes. Design Phase The system configuration agreed to in the Preliminary Design Review is reduced to construction drawings according to industry practice. The appropriate performance sensors for the specific sites are defined by the Government. In coordination with the team member preparing the final construction drawings, the sensor installation details and procedures (31 are integrated into the final construction drawings. Final Design Review This review is conventionally calleda90 percent review. The purpose of this review is to approve the final and complete construction installation drawings and specifications prior to release for competitive biddings. 'These 4

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documents have Iwcn prepared in the design phase based on approved prelimin:cry desigi, and configuration. The estim, -d cost of the project is a significant review item as well as .ill system definitivt detAls not approved conceptually in the preliminar y rrvieu. They eompliancc , of ;ill (•Icments 4 the project design with the Interim Performance Criteria 151 and all state and local r(,)des is evalwited. Other specific review items are, for example, detailed checks of structural, electrical, and site drawings for technical adequacy, complcAUIWsn, clarit` for competitive bids, and project control during and after construction. Th(r control eystem operating modes, operating; paraineter settings, and building instillation locations are also evaluated in detail. Competitive Bidding, Construction Contract Award, and Construction Phase The complete and approved drawings and six±cifications permit the Selection of an acceptable bidder on the basis of cost and defined task. This s0ection is dome, b>• the organization with whom the ( g overnment has contracted for the demonstration site. If no acceptable bids are received within the allocatcd project funds, than a design-to-cost exercise may be performed tr, reduce some element of the project scope so that aii acceptable bid within the allocated project funds can be obtained by competitive bidding. Acceptance Test Phase Following eompleti . ,n of tlu: c onstrucLion phasu, ti Aar energy system will be oywrated to evaluate the design conditions of th-^ fall-,wing;: a. Collector performance, flowrates, and flow urulto,mity b. Storag u device performance, heat loss, and internal plumbing; ;adequacy. c. Transport system floNt rates and heat loss d. Airconditioner performance, C.O.1)., air and water flowrates, now balance, and distribution e. Control system adequacy and operating parameter set points, and control stability

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f. Heating system performance, .air and water i7owrates, flow balance, and distribution g • Auxiliary or alternate heating/cooling system operation performance and ;nitomatic cut in h. All pumps and fans electric power requirements. During this operation, the performance measuring sensors and the. Site, Data Acquisition System are used to measure and record performance. A special "on site monitor" (OSbl) is provided so that performance : ignals recorded in the Site Data Acquisit ion System can be read in engineering units at the SiW. Current program plans are for each site to have temporary use of an OSiI for the period required to perform acceptance testing. Adjustments or changes to the system tc.) achieve desired or optimum performance are made during ahis period. Operational Phase During this period, which may be up to 5 years, the Site Data Acquisition Systen ► rec()rcl.s the performance and transmits these data to a central computer in Huntsville, Alab.una. No change can be made to the system configuration in this period without AIShC /ERDA approval. These program elements were used as a general guideline for each project; however, significant deviations were required on several sites due to the following: a. The selected sites varied in project status from conceptual design, where all elements of the general program guidelines could be used, to several projects that were already complete and required only definition and installation of the performance measuring sensors and Site Data Acquisition System. b. The site size/ complexity and thus the propx>sed site team (the PON requested a site owner, an :architect /engineer, and project manager) varied from large sites im,olving major national corporations with large supporting technical organizations (both architects and engineers) to small projects where one man Served nc-arly all functions. The contractual relation with all 32 selected sites was negotiated before .tune 30, 1976, and Table 1 defines the projects including cost and Table l 6

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pre sviAs the project status. The data of T;ihles 1 and 2 show that of the total progriva coht of 7.9 million, 2.1 million (or 26.9 percent) has bean completely through the design and construction phase+. Another 1. x million (or 22.9 percent) is currently under fixed price construction contract: The rvniainder of the project work valued at 4. s) million (or 50.2 percent) has not been advertised for cwnpetitive bidding. In achieving the current program status, a significant amount of experience has Ixwn obtained by the program participants, lx ►tli industry and government. The condensed summary of the "lessors learned" information presented in dsls re portis the first publication of this type of information over the entire program ( individual papers on the technical aspects of several projects have been published) . The compilation of significant program experience is separated into technical design and ;management areas and is presented in fables 3 and 4. I'he information is presented in general terms to show its possible impact for any other program and ;tlso tf ► minimize its identification with any specific ;.roject and thus 1 ►reelude any possible reflection on anY firm or individual. In addition to the problems solutions ► nform-Aion co ►ntained in this report, it was decided to collect additional program d^ta concerning financial at: recommended program ch ►nges from each of the site owners as well as architect and/or engineer. A joint committed of the ASIIRAE and the. AIA Research Corporation prepared a questionnaire and discussed the answers to these quustions u ith each resix)ndent. The results of this questionnaire have been reduced to a draft report by the joint ASHRAE and MA Committee. The report is expected to be publiah ► !d very soon and be available through Ati11RAE, AIA, and government sources. CONCLUSIONS The overall gual of the Government solar heating and cooling program is tG stimulate the creation of an industry that will ultimately provide solar heating and cooling s ystems competitive will► conventional powered heating and Cooling systems without Government funding suPport. The commercial a,olar heating and voclinp, demonstration progra.n ► has contributed to this overall goal in the following areas: 7

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. Public visibility and ;recess — The mount Itushmore: Site and the Florida Visitors Center together will Ix, visited by over 50 000 people per day during peak sew4on. It is projected that over 2 000 000 people per year wlll visit the 32 sites reelected in the first year. b. Project experience and desigr. data dissemination — The project reports, including as-built drawings, installation, operation and maintenance mcrnuals, are to 1xi provide-d to the "'at onal Technical Information Center for ► public: access. e. The initial w l - f-t ► ng in March of 1976 with industry and teehniccd associations provided invaluable inputs into the prograni structure. A major product of this meeting was precluding aerospace procedures or terminology from being initiated in a program where it was not appropriate or desired. A second meeting was held in March 1977 with Uw same+ previously mentioned organizations and also the President and reprvsvntaU%(!r, of the Solar Energy Industry Association. A review of what has been accomplished in this program was performed, ;wd an effective communication procedure wits established between NASA and the technical/industry organization. Periodic reviews with these organizations wed possibly others are planned for the future. Some of the early demonstration projects have long economic "pay back periods" defined as the cost of the project divided by cost of energy saved. However, many of the commercial organizations involved in the program have expressed firm intentions of pursuing additional efforts in solar heating and cooling as a result of participation in the PON Program. The demonstration program therefore has developed a "multiplier effect." Based on expressed stated intentions of many site participants, the multiplier effect can be as high as 5 to 10 where for each dollar of Government funds in the program between 5 to 10 dollars of non-government funds may be introduced into solar heating; and cooling. The stimulated applications vary from ;additional applications of solar heating and cooling to manufacture and or distribution of :solar heating and cooling; l,rociucts such as collectors, storage devices, and control devices. An observation of the program has been the successful utilization of architects and engineers experienced in the conventional construction industry to design successful solar heating and cooling projects. The conventional industry design and competitive bid procedures have resulted in cost conscious design and construction in the proiTam.

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INSTRUWNTS SENSOR,'. l ^^ SOAs SITE DATA ACOUISITION ::JBSYSTEM TELEPHONE INTERFACE SENSOR WIRES JUNCTION 80X I ID J — 80X ELECTRICA INTERFACE 3-90X/SDAS INTERFACE CABLE (MAXIMUM SEPARATION FOUR FEET) Ill V/',' CENTRAL DATA PROCESSING FACILITY 1'igurc 1. site data acquisition ,% -tem. 9

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REFERENCES 1. Program Opportunity Notice DSF. 75-2, Closing Date Novemlx-r 2f, 1975, ERDA, Division of Solar Energy. Program Opport«nity Notice USE 76-2, Closing Date November 9, 1976, ERDA, Division of Sola: Energy. 3. Instrumentation Installatien Guidelines for the National Solar Heating and Cooling Demonstration Program, SHC-1006, August •1, 1976. 4. Thermal Data Requirements and Thermal Performance Evaluation Procedures for the National Solar Heating and Cooling Demonstration Program, NBSIR 76-1137, August 1976. 5. Interim Perform.Lnce Criteria for Solar Heating and Cooling Systems in Commercial Buildings, NBSIR 76-11h7, Novemlx:r 1976. G. Humphries, XV. R. , Hewitt, H. C., and Griggs, E. 1. , "Fluid Manifold Design for a Solar Energy Storage Tank," NASA -TI4I-X-6 .1990, June 1975. 26

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APPROVAL THE SOLAR HEATING AND COOLING COMMERCIAL DEMONSTRATION PROGRAM - SOME EARLY PROBLEMS AND RESULTS BS Robert L. Middleton The information in this report has been reviewed for security classification. Review of any information concerning DepLu-tment of Defen3e or nuclear energy activities or 1mograms has been made by the A1SFC Security Classification Officer. This report, in its entirety, has been determined to he unclassified. i) 6. C. SWEAIIING); 4 Manager, Speeia rojeets Office NASA --MSFC 27